Customer project number 2 2007 TRANSIT MK7 T260 85PS

[paul2012]

2007 TRANSIT MK7 T260 85PS Ex Royal Mail with 62,000 miles on the clock

Members mk7 I have in for repair etc.

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1st on the list. Change battery as it's flat & start engine.

Greeted with a loud knocking sound emanating from engine..... See vid here https://www.youtube.com/watch?v=ePTvmrRIP40. & loads of smoke from exhaust

With tapping from the top I'm certain there's a slight knock from bottom end as well.
More investigation is required. So stay tuned.......

[paul2012]

Ran IDS on mk7. No DTC's stored Obviously a mech fault

Done a compression test. Cylinder 4 was too low
Replaced injectors with new seals etc & fuel pump. Made know difference at all.

Removed cylinder head to find......

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Cylinder 4 is badly scored, possibly broken piston rings
Signs of piston being burnt away...



In simple terms engine is shot

[paul2012]

Engine conversion to be done.

Engine choice. 2.0 TDCI from a Ford Mondeo MK3

[paul2012]

Lets get started.

Stripped down...

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[paul2012]

A few alterations...

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[paul2012]

Using full mk6 2.0 TDCI 125ps wiring looms & modules from front to back

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[paul2012]

ABS dropped for standard brakes....

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[paul2012]

Engine fitted with mk6 main engine mount....

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[paul2012]

Front end refitted & relocated power steering reservoir....

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[paul2012]

Interior refitted....

Now equipped with A/C, heated front screen & front fog lights.

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[paul2012]

MOTed & on the road...

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[tony&kasia]

A few more updates will be loaded shortly

[tony&kasia]

I bought the front grill in frozen white from Loot


Got the grill painted in colorado red.
Also but these step covers,


Front fogs & grill was all fitted by paul 2012

Also bought these 18'' alloys


A new DAB radio & parrot hands free


Changed the switches & blanking plate to a trendy silver that was removed from a C Max


Fitted these rear tripple seats & rear bulkhead


Bought a sliding door with privacy glass all fitted for a bargain price of 50.00
Also had the repairs done to all the N/S & the door fitted & all painted

Also the wheels fitted as well


The van is now on 77000 miles.
It has since passed another MOT with no problems.

But i have had all these things done as well,
Electric mirrors, Upgraded the electric windows to mk7, Focus st door handles, The air con all serviced up,

Brand new genuine front wheel bearings & disc & pads, New battery, Towbar, Privacy windows on both sides,
New water pump & thermostat, New drivers seat cover, New front & rear bumper corners & rear bumper cover all genuine parts,
All these parts i have found on the bay & have picked them up quite cheaply. Def not Ford prices,

Also had the injectors replaced last month.

I have just picked up some Tourneo seats with arm rest and the newest mk7 seat patterns,
I have not fitted these as yet but i am looking for the drivers seat & front double seat in the same pattern

I will post a few more pics a bit later. I have had a few probs with photo bucket.
May i thank you paul2012 for all what you have done to this project You are a top man.

Next job after christmas is some paint work on the drivers side

[paul2012]

I will post a few more pics a bit later. I have had a few probs with photo bucket.
May i thank you paul2012 for all what you have done to this project You are a top man.

Next job after christmas is some paint work on the drivers side

No problem m8.

[tony&kasia]

This is the rear bumper i bought for 30.00 all genuine parts
I only wanted the plastic middle section but might as well fit the rest as they are nice & shiny

Will be fitting this after some paint work on the o/s.